E-BikeTouring: Next step:

Remove a stuck seat post from the recently acquired Surly Pugsley.

This seat post is stuck. It has probably been in that seat tube for 10 years.
Aluminum seat posts and steel frames is not a good mix. If the seat post is not removed, I will need to get another frame.

This was a challenge.

The usual steps were taken.

- trying to muscle out by twist the saddle.
- lubing the top of the tube with penetrating oil
- Removing the bottom bracket and soaking the seat tube from the bottom with penetrating oil.
- Using heat gun to heat up seat tube
- Putting seat post and vise and twisting the frame.

Before the last ditch effort was done, I took the bike to my Local Bicycle Shop.
They reported they may have success removing stuck seat post.

The Local Bicycle Shop tried their best to remove it.

They drilled a hole in the post and tried to twist it out.
Put it is a heavy Duty Vise.

The Post did not budge or twist at all !

THIS TIME THEY FAILED.

Stuck Seat Post

stuck seat post after Local Bicycle Shop failure

The Last thing to try:

The next - step was to cut the seat top out.

Often a cut or a few cuts in the seat post the post to twist or the post collapses and the pieces can be pulled put of the set tube.

But NOT this seat post!

After 4 separate cuts, using a reciprocating saw (9inch wood 6t in blade), each 1/4 strip of the seat post remained firmly attached to the steel seat tube wall. The post would not break away from the seat tube. It was galvanized bad.

Using a small chisel, about a half inch piece of the seat post quarters could be pried away from the seat tube and then folded in. The folded pieces were then drilled and broken into tiny pieces using an 1 inch wood drill bit. This process continued down the seat tube.

Eventually that last of the seat post was destroyed and removed.
It was a long time consuming process.

seat tube before repair and resurfacing

The seat tube did have a little damage with this process. J-B Weld Steel Stick was used to repair and resurface the inside of the seat tube & the lip of the tube. A steel washer was shaped to be welded to the seat tube at the bottom on the expansion slot of the seat tube to provide support.

The inside of the seat tube was then cleaned and polished with steel wool. The seat tube was then blown out with air to remove fragments and a coat of grease applied in the seat tube.

The new seat post was then greased and put into the seat tube. The seat post fit snuggly... but smoothly and most of all very sturdy. A new seat post clamp applied.

It was a Hard job, but the Surly Pugsley Bicycle Frame should be 'good to go' for more miles.